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GUIDANCE DOCUMENT FOOD SAFETY fssai.gov.in/dam/jcr:62dd83b1-4706-4dbd-9655-43c9c9f1f3b8/Guidanc · PDF filetrained appropriately to implement the good manufacturing practices and

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    GUIDANCE DOCUMENT

    FOOD SAFETY MANAGEMENT SYSTEM (FSMS)

    FOOD INDUSTRY GUIDE TO IMPLEMENT GMP/GHP

    REQUIREMENTS

    MEAT AND MEAT PRODUCTS (POULTRY)

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    Food Industry Guide to implement GMP/GHP requirements

    MEAT AND MEAT PRODUCTS: POULTRY

    Based on Part IV of Schedule 4 of Food Safety & Standards (Licensing &

    Registration of Food Businesses) Regulation, 2011

    First Edition February 2018

    Online available at www.fssai.gov.in

    Disclaimer

    It is to be noted that this guidance document does not intend to replace any legal provision

    of Food Safety & Standard Act, 2006 & regulations thereunder. Further, wherever the

    provision of this document conflicts with Part IV of Schedule 4 of Food Safety &Standard

    (Licensing and Registration of Food Businesses) Regulation, 2011 or any other regulation

    under Food Safety & Standard Act, 2006 for that matter, the provision given in the

    Regulations shall prevail.

    http://www.fssai.gov.in/

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    PREFACE

    The Guidance Document on Food Safety Management System (FSMS) is

    prepared with intent to provide general guidance to Poultry meat Industry to

    ensure that critical food safety related aspects are addressed during the entire

    supply chain from slaughtering, processing till retail.

    This document mainly contains pragmatic approaches which a business can

    adopt during manufacturing of poultry meat and meat products. However,

    manufacturers may adopt higher stringent levels, depending on the needs. The

    use of this guidance is voluntary and food business operators may comply with

    the requirement of the Regulations according to other established best

    practices.

    It is important that food handlers involved in the poultry meat industry are

    trained appropriately to implement the good manufacturing practices and

    good hygiene practices to ensure food safety.

    We acknowledge the contribution of the experts from the technical panel of

    FSSAI along with CHIFSS (CII-HUL Initiative for Food sciences) team for

    developing this document.

    Pawan Agarwal CEO, FSSAI

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    TECHNICAL EXPERTS

    Sh. Arabind Das Chief Operating Officer, M/S Godrej Tyson Foods Ltd., Mumbai Sh. Uday Sawant General Manager, M/S Venkys India ltd., Pune Ms. Sudha Singh Food Safety Consultant Sh Ashwani Rajput Executive Director, M/S Suguna Foods Pvt Ltd., Coimbatore Ms. Surbhi Datta Counsellor Food Safety & Quality, CII FACE, Delhi Dr. Sujata Singh Assistant Director (Tech) FSMS, FSSAI Ms Suneeti Tooteja Director FSMS, FSSAI

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    SCOPE This document is applicable for food businesses involved in the entire or any part of the poultry supply chain i.e. from slaughtering till retail. It provides the safe food practices to be followed by the food business to control food safety and related hazards and risks covering poultry slaughter and poultry meat processing along with its storage, distribution and retail. Poultry can be defined as domestic fowls, including chickens, turkeys, geese and ducks, raised for the production of meat. This document generally mentions chickens at various places which should be applicable for all other birds falling under Poultry species.

    GUIDANCE TO READ THE DOCUMENT This document is written with a purpose to guide the food businesses especially the small and medium sector, both existing and newly established businesses. The document is divided into five main sections. The first section gives an overview of the poultry industry in India and the rising need for food safety in the sector. The second section gives an introduction to process flow and a brief on relevance of main processing steps. The third section is the critical part of this document and contains guidance on implementation of good hygienic practices and good manufacturing practices at all the steps throughout the food chain, as outlined in Part IV of Schedule 4 of Food Safety & Standards (Licensing & Registration of food Businesses) Regulation, 2011. Readers will also find some recommended practices which are currently practiced in poultry industry. The document has specified requirements where compliance is essential and obligatory for food businesses and in such cases the word shall or must is used. In addition, certain good practices have also been recommended for food safety operations and in such cases the word should is used. Readers are requested to make sure the difference between shall and should while reading, analysing, and putting the document into practice. The fourth section of this document is recommendatory in nature to help the industry understand basic knowledge and implementation criteria of Hazard Analysis and Critical Control Point (HACCP). The readers will find two forms of tables in this section: Hazard Analysis and HACCP Plans. Tables of Hazard Analysis is expected to help the industry to identify the food safety risks related to each processing step, analyse, to identify the Critical Control Points (CCPs) along with recommended corrective actions and other related information. Sample HACCP Plans have been taken from some established practising poultry industries. These plans are provided for understanding and could be used a reference by the industry and modified or altered based on their specific operations after conducting a detailed risk / Hazard analysis. The fifth section provides an inspection checklist for Food Business Operator to audit their facility & operations. The FBOs can evaluate themselves based on the indicative scoring. The last section gives important templates and forms which will be required by FBOs to maintain the records. This includes mandatory forms as prescribed by FSSAI & few templates for maintaining records of processes critical for food safety.

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    CONTENTS

    ABBREVIATIONS.08

    LIST OF FIGURE09

    LIST OF TEMPLATES.10

    A. OVERVIEW OF POULTRY MEAT INDUSTRY IN INDIA..11

    B. MANUFACTURING/PROCESSING PARAMETERS FOR POULTRY AND POULTRY

    PRODUCTS.13

    1. Process Flow charts and Details

    2. Loading, Dispatch, Warehousing, Transportation, Retail Precautions related to food

    safety & Quality

    C. PRE-REQUISITE PROGRAMS.24

    I Establishment Design and Facilities

    1. Location and Surroundings

    2. Premises and Rooms- Construction, Design, Layouts, Internal Structures and Fittings

    3. Equipments & containers

    4. Facilities and Utilities

    II Control of Operation

    1. Transportation and Receipt at Slaughter House

    2. Storage of Raw and packaging materials

    3. Meat and Meat Products (Poultry) processing including pre-processing

    4. Allergen Management

    5. Packaging Material and Meat Storage including warehousing

    6. Food Packaging

    7. Rework & control of non-conforming products

    8. Transportation of Meat and Meat Products (Poultry)

    9. Food Traceability& Recall

    10. Quality Control

    III Establishment Maintenance and Sanitation

    1. Cleaning and Sanitation

    2. Maintenance

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    3. Pest Control

    4. Waste Disposal Management

    5. Others

    IV Establishment Personal Hygiene

    1. Health Status

    2. Personal Cleanliness

    3. Personal Behavior

    4. Visitors

    V. Establishment Product Information and Consumer Awareness

    1. Product Information & Labeling

    2. Consumer Awareness & Complaint Handling

    VI Establishment Training and Management

    1. Training

    2. Management and Supervision

    VII Establishment Audit, Documentation and Record Keeping

    1. Self-evaluation and Review

    2. Audit, Documentation and Records

    D. Sanitary and Hygiene Requirements for Small Slaughter House and Retail Store54

    E. HACCP IMPLEMENTATION (POULTRY PROCESSING)58

    Hazards associated with Poultry meat manufacturing & HACCP implementation

    for important control measures

    Possible Hazards in Poultry Meat and Processed Poultry Products

    REFERENCES / SUGGESTED READINGS

    Annexure 1- Templates72

    Annexure 2- Inspection Checklist-89

    a. Slaughter House

    b. Meat Processing Units

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    ABBREVIATIONS AM Ante Mortem Examination CCP Critical Control Point ETP Effluent Treatment Plant FEFO First Expiry First Out FIFO First in First Out FMFO First Manufactured First Out FSMS Food Safety Management System HACCP Hazard Analysis Critical Control Point QA Quality Assurance ISO International Organization for Standardization GMP Good Manufacturing Practice GHP Good Hygiene Practice PM Post Mortem Examination MSDS

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    Material Safety Data Sheet

    LIST OF FIGURES Figure no. Title

    1. Ante-Mortem of Poultry

    2. Washed Carcass after Inner & Outer Washing

    3. Processing hall for Deboning & Cutting Portioning

    4. Retail Shop Display

    5. Entry to food establishment

    6. Doors and windows covered with wire mesh to prevent entry of dirt, dust, pests and birds

    7. Install covered drainage system inside the premises

    8. Gender specific toilets; clean toilet facility

    9. Protected Tubelight

    10. Stunning

    11. Floor should be in kept clean and tidy

    12. Cleaning Materials and Placement

    13. Dedicated chemical (cleaning/ pest control) storage room with provision of lock and key

    14. Maintena

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